Multilayer Insulating Panel with Embossed Sheet for Adhesion Strength
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Solution Overview
Problem
Existing insulating panels for building heating systems, particularly those with embossed sheets, suffer from ineffective adhesion and mechanical instability, leading to potential detachment issues, especially in wall installations, and have complex, time-consuming manufacturing processes.
Innovation Solution
A multilayer insulating panel featuring a polymeric embossed sheet with bosses and recesses, combined with a connection layer, provides enhanced adhesion and mechanical resistance, using polyurethane foam as the main insulating material and alternative manufacturing methods for improved efficiency and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an embossed sheet is glued to a polystyrene insulating sheet, then the sheet provides mechanical support and positioning for heating wires, but the adhesion is ineffective and the sheet may detach
Solution Approach 1:
The patent combines an embossed polymeric sheet with a foam insulating material to create a composite structure. The embossed sheet provides mechanical support and positioning features (protrusions and recesses) while the foam material provides insulation and additional bonding surface area, creating a composite material system that achieves both mechanical strength and thermal insulation properties effectively
Solution Approach 2:
The embossed sheet features three-dimensional protrusions and recesses that create additional bonding surfaces in the vertical dimension. This dimensional transformation from a flat two-dimensional surface to a three-dimensional textured surface increases the effective adhesion area and mechanical interlocking capability between the sheet and the insulating material
2Strength
If the embossed sheet is molded together with the polystyrene sheet, then adhesion is improved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent separates the manufacturing of the embossed polymeric sheet from the insulating foam material. The embossed sheet is produced independently with its mechanical support features, then assembled with the foam insulating material. This segmentation allows each component to be optimized separately and simplifies the overall manufacturing process compared to simultaneous molding
3Loss of energy
If traditional insulating panels are used, then heat insulation is provided, but the panels have large thickness and poor adhesion
Solution Approach 1:
The combination of the embossed polymeric sheet and foam insulating material creates a composite panel structure that achieves superior thermal insulation performance with reduced thickness. The foam material provides high insulation efficiency while the embossed sheet adds minimal thickness while providing mechanical functionality
Solution Approach 2:
The patent changes the physical and structural parameters of the insulating panel by introducing the embossed sheet with specific protrusion and recess geometries. This structural parameter change enhances both the thermal insulation efficiency and the mechanical adhesion properties, allowing for thinner panel designs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures effective adhesion of the embossed sheet to the insulating layer, enhances mechanical resistance, and allows for continuous manufacturing, reducing complexity and time, while offering superior heat insulation with thinner panels, thus addressing the drawbacks of existing panels.
Implementation Method 1
A multilayer insulating panel (100) for the installation of an electric heating system comprises a main layer (1) manufactured from a thermally insulating material... a sheet (2) made of a polymeric material operatively associated with one of the first (10) or second (11) surface (10, 11) of the main layer (1)... a connection layer (3) fixed to the second face (21) of the sheet (2), wherein the connection layer (3) is interposed between the second face (21) of the sheet (2) and one of the first (10) or second (11) surface (10, 11) of the main layer (1)
Implementation Method 2
a main layer (1) manufactured from a thermally insulating material... they reduce the propagation of heat towards the slab... such a main layer (1) of panel (100) comprises polyurethane foam
Implementation Method 3
Floor electric heating systems generally comprise electric cables operating as electrical resistance or electric heating wires which, if crossed by electric current, heat up due to the Joule effect, thus transferring heat to the surrounding environment
Data Source
AI summary
A multilayer insulating panel is for the installation of an electric heating system having electric heating wires in a subfloor or in a wall of a building. The panel includes a main insulating layer including a first surface and a second opposite surface. A sheet made of polymeric material is operatively associated with one of the first or second surfaces. The sheet has a first face and a second opposite face and includes reliefs equally spaced apart on the first face to fix the electric heating wires on the first face in a reversible manner. A connection layer is fixed to the second face of the sheet. The connection layer is interposed between the second face of the sheet and one of the first surface or the second surface of the main layer following the association of the main insulating layer with the polymeric sheet.